DC shunt motorsType MGXRK 090 ... 160
MGXQU 080 ... 160MGXQK 063 ... 160
384 924 GB
Operating instructions
2
Titelbild K33.0002 / K33.0003
Copyright Lenze GmbH & Co KG, Postfach 101352, D--31763 Hameln
First read operating instructions, then act !
Manufacturer:
Lenze GmbH & Co KGPostfach 101352D--31763 Hameln
Location:
AerzenHans--Lenze--Straße 1D--31855 AerzenTel.: (05154) 82--0Fax : (05154) 82--4040
Country of origin and year of construction:
See nameplate (chapter 4.4)
These Operating instructions are valid for DC shuntmotors of the series:
-- MGXRK 090 ... 160
-- MGXQU 080 ... 160
-- MGXQK 063 ... 160
BA 13.0005Author: Motor Division2nd edition 06/97
3
Contents Page
1. Explanation of symbols 4
2. General safety notes 42.1 Users 42.2 Safety notes 4
3. Transport and storage 43.1 Unpacking 43.2 Transport within the site of installation 43.3 Conditions of storage 43.4 Waste disposal of the packing material 4
4. Product description 54.1 Function description 54.2 Area of application 54.2.1Other areas of application 54.3 Type code 64.4 Designation / Nameplate 74.5 Technical data 74.6 Emissions 8
5. Assembly / Installation 95.1 Preparations 95.2 Site of installation, nominal conditions, and influencing factors 95.3 Installation 95.4 Electrical connection 95.5 Parts for attachment 11
6. Commissioning and operation 126.1 Checking before commissioning 126.1.1 Measuring the insulation resistance 126.2 Function test 136.3 Inspection 136.4 Fault -- Cause -- Remedy 14
7. Maintenance / Repair 157.1 Maintenance periods 157.2 Wear check of carbon brushes 157.3 Wear check of the collector 177.4 Recognition of incorrect operating conditions 187.5 Waste disposal of the product 19
8. Spare parts 208.1 Spare parts lists 208.2 Ordering example for spare parts 22
Manufacturer’s Declaraction
Service addresses
4
1. Explanation of symbolsDanger !General danger (Danger of persons and/ormaterial)
Use in hazardous areas is prohibited.
Dangerous electrical voltage.
High temperature.
Assembly or dismantling using hammers orother striking tools is prohibited.
Note: Use raw material for recycling.
2. General safety notesFirst read, then act !
2.1 UsersAssembly, commissioning, operation, andmaintenance only by specialists or skilledpersonnel.
2.2 Safety notesn Read operating instructions beforeasembly, commissioning, operation, andmaintenance.
n Observe safety notes and warning symbolsin the individual chapters.
n Observe regulations for safety andprevention of accidents.
n Do not operate in hazardous areas !
n Only intended use is permissible.
n For non--intended use and non--authorizedmodifications, the product liability andwarranty are invalid.
3. Transport and storage
3.1 Unpacking¯ Take drive components out of the packingand check for transport damages.
¯ Check if the shipment is complete.
3.2 Transport within the site of installation¯ Tranport motors only with sufficiently strongtransportation tools or hoists. Ensure safefixing.
Some of the motors are equipped witheyebolts for a safe fixing at the hoists (forweights see chapter 4.5).
¯ Transport motors vibration--free
¯ Avoid strong shocks and impacts
3.3 Conditions of storage¯ Location of storage:
-- vibration--freeIf there is a risk of vibration, it isrecommended to rotate the rotor in itsbearings once a week.
-- dry without aggressive media-- no dust-- no fast temperature changes¯ Corrosion:
-- steel parts are protected against corrosionby the factory. Do not remove thisprotection, check in intervals of approx.three months and renew, if necessary.
In case of intermediate storage> 3 months¯ Collector:
-- take off carbon brushes from the collectorsurface
-- protect collector by a piece of paperaround the running surface.
3.4 Waste disposal of the packing materialn Packing material can be recycled.
3.4
5
4. Product description
4.1 Function descriptionThe motors of the MGXRK, MGXQU andMGXQK series are separately excited DCshunt motors.The motors of the MGXRK series aresurface--cooled in IP54 enclosure and have around, ribbed housing. The motors of theMGXQU and MGXQK series have a squarecross--section, are designed in IP23Senclosure and internally ventilated.The motors have fully--laminated stators andare externally cooled by axially or radiallymounted blowers in their standard design(type GF...). With reduced power, the motorsare also supplied with speed--dependentself--ventilation (type GE...) and withoutventilation in self--cooled design (type GS...).
4.2 Area of applicationn Do not use in hazardous areas !
n Fire risk !Avoid contact with inflammable material !
¯ Ambient temperature must be up to+40 5C, higher ambient temperaturerequire a power reduction.
¯ Installation height up to 1000 m above sealevel,installation above 1000 m above sea levelrequires a power reduction.
¯ Observe temperature class F (155 5C)according to DIN--IEC 34 / VDE 0530. If thelimit temperature is exceeded, theinsulation is weakened and damaged.
¯ Enclosure to DIN--IEC 34 is IP54 or IP23S.The actual enclosure can be obtained fromthe nameplate (see chapter 4.4.)
¯ No tropical insulation.
¯ Designs (to DIN--IEC 34 part 7)MGXRK: IM B3, IM B5, IM B14MGXQU, MGXQK: IM B35 and IM B34
The motors can be mounted in anymounting position. Vertical arrangementsaccording to DIN--IEC 34 part 7 arepossible.
4.2.1 Other areas of application¯ For other areas of application a power ortorque reduction is required using thefactors of the following table.
The permissible continuous power iscalculated from:
P’ = kJ ¡ kh ¡ Pdwith Pd being the permissible continuoustorque under normal conditions.The torque can be calculated accordingly:
M’ = kJ ¡ kh ¡ Md .Md being the permissible continuous torqueunder normal conditions.
Cooling air temperature5C 40 45 50 55 60
Power reduction kJ 1.00 0.95 0.90 0.83 0.77
Power reduction with different ambient or cooling air
temperature
Installation height above sealevel in m 1000 2000 3000 4000 5000
Power reduction kh 1.00 0.92 0.83 0.77 0.67
Power reduction with different installation height
¯ If the actual form factor FF*≥1.05, a powerreduction or torque reduction is alsorequired.
The permissible continuous load is calculatedfrom:
P’= ( 1.05 / FF* ) ¡ PdThe torque is calculated as follows:
M’ = ( 1.05 / FF*) ¡ MdThe form factor can be improved, amongothers, by using armature chokes. Armaturechokes which are suitable for Lenzecontrollers can be obtained from the technicaldescriptions of the controllers or from yournearest Lenze representative.
6
4.3 Type code
MGXXX XX XXX -- XX
Motor
Current type
MG = DC current
Cooling / Ventilation
F = forced--ventilatedE = self--ventilated (cooling effect depends on the speed)S = natural cooling ( cooling by convection and radiation)
Design / Housing
Q = Smooth housing, squareR = Ribbed housing, round
Type of machine
K = compensatedU = not compensated
Attachments
BI = Brake and pulse encoderBR = BrakeBS = Brake and resolverBT = Brake and tachoBU = Brake + Tacho + pulse encodeIG = Pulse encoderRS = ResolverTA = Tacho, analog sensorTI = Tacho + pulse encoderXX = no attachments
Size
Axis height in IM B3 design in mm
Length
0 = VS very short1 = S short2 = M middle3 = L long4 = VL very long
Pole pair numbe
1 = p=1 (2--pole)2 = p=2 (4--pole)
11
12
13
7
4.4 Designation / NameplateThe nameplate consists of the following data(tolerances according to DIN--IEC 34):
Lenze GmbH & Co KGHans--Lenze--Straße 1, D--31855 Aerzen
➀ ➁ ➂➃
➅ ➆ ➇ ➈➉ 11 12
13
T374595
➄
➀ Motor type (G for DC shunt motor)➁ Motor type of the form MGXXXXX XXX -- XX➅ Enclosure➃ Commission number, including year of
construction➄ Motor number➅ Rated armature voltage➆ Rated armature current➇ Rated speed➈ Rated power➉ Rated excitation voltage
Rated excitation currentTemperature classAttachments (B--side)
4.5 Technical dataThe rated powers indicated on the nameplateare based on a form factor of the armaturecurrent of FF = Ieff / Iarithm. = 1.05. With higherform factors a power reduction according tochapter 4.2.1 is required.
In the following, the technical ratings andmain dimensions (overall dimensions) of thestandard motors without B--side attachmentswith separate blower and with filter elementare listed.
Table 1: Technical data of MGFRK standard motors (without B--side attachments) :
Motor size MN J Fr Fa Fr,v Weight L W H
Nm kgm2 N N N kg mm mm mm
MGFRK 090-22 5.8 0.0040 780 440 2100 21 492 253 200
MGFRK 100-22 8.9 0.0061 1000 500 2700 28 530 284 250
MGFRK 112-22 15.5 0.0142 1500 500 2800 40 538 298 280
MGFRK 132-22 32.5 0.0411 2200 1100 4500 84 709 354 325
MGFRK 160-32 73.7 0.1120 3000 1250 5100 172 941 406 376
Table 2: Technical data MGFQU standard motors (without B--side attachments) :
Motor size MN J Fr Fa Fr,v Weight L W H
Nm kgm2 N N N kg mm mm mm
MGFQU 080-22 18.3 0.0087 1200 400 1950 36 467 235 335
MGFQU 100-22 36.1 0.0237 1600 580 3100 65 520 235 375
MGFQU 112-22 73.8 0.0475 2300 1000 4900 115 660 259 451
MGFQU 132-32 140.5 0.1120 2300 1350 4900 170 760 275 525
MGFQU 160-22 279.0 0.2452 4950 3580 9700 250 864 508 606
MGFQU 160-32 343.0 0.3200 5050 3580 9900 285 944 508 606
Tab. 3: Technical data of MGFQK standard motors (without B--side attachments) :
Motor size MN J Fr Fa Fr,v Weight L W H
Nm kgm2 N N N kg mm mm mm
MGFQK 063-32 7.0 0.0032 750 400 1100 19 451 235 299
MGFQK 100-32 34.3 0.0170 1600 580 3100 65 520 247 427
MGFQK 160-22 289 0.2452 4950 3580 9700 250 864 508 606
MGFQK 160-32 356 0.3200 5050 3580 9900 285 944 508 606
The torques and weights indicated in thetables are only considered to be guidelinesfor the dimensioning and bases.
The actual technical data must be obtainedfrom the nameplate of your motor(see chapter 4.4).
8
Signs:MN = Rated torqueJ = InertiaFr = Permissible radial loadFa = Permissible axial loadFr,v = Permissible radial load with
reinforced bearingGew. = Motor weight (incl. blower)L = Motor lengthH = Motor heightW = Motor width
-- The permissible loads mentioned in table1 to 3 are understood to be either radialloads or axial loads.
K12.311--08
Fig.1: Point of application of radial and axialloads
4.6 Emissionsn Risk of burning !The surface temperature of the motors canbe up to 905C depending on the operatingstate.
¯ Noises:
The noise level of 70 dB(A) is notexceeded by the following motors:
MGFRK 090--22MGFRK 100--22MGFQU 080--22MGFQK 063--32
Noise level of the other motors:Motor type Noise level
dB(A)
MGFRK 112-22 75
MGFRK 132-22 76
MGFRK 160-32 78
MGFQU 100-22 76
MGFQU 112-22 81
MGFQU 132-32 83
MGFQU 160-22 86
MGFQU 160-32 86
MGFQK 100-32 76
MGFQK 160-22 86
MGFQK 160-32 86
¯ Dusts :Scuff of carbon brushes inside the motorwith enclosed motors,in the outlet air of enclosed--ventilatedmotors.
Composites:-- different metals-- graphite-- possibly epoxy resin or other bondingagents
9
5. Assembly / Installation5.1 Preparations¯ Unpack motors and check for transportdamages.
¯ If necessary, remove fastening device ofthe key and residuals of the corrosionprotection.
¯ The motors were checked at the factoryand are ready for use.
5.2 Site of installation, nominal conditions,and influencing factorsn Do not operate in hazardous areas !
The motors are designed for the followingnominal conditions:¯ Supply with half-- or fully controlled bridgerectifier
¯ Rated power is based on a current formfactor of
FF = Ieff / Iarithm. = 1.05(see chapter 4.2.1)
¯ Ambient or cooling air temperature up to+40 5C (see chapter 4.2.1)
¯ Installation height up to 1000 m above sealevel (see chapter 4.2.1)
¯ Operation within the permissible controlrange or self--ventilated motors
¯ Ensure unimpeded flow of incoming andoutgoing air
¯ Avoid re--circulating of warm outlet air bythe motor
5.3 Installationn Ensure that no foreign matter penetratesinto the motor during assembly andcommissioning!
¯ Prepare fixing according to the design,weight, and torque of the motor.
¯ Before fixing the motor, the foot and flangefaces must evenly rest on. Insufficientalignment of the motors reduces the life ofthe bearings and transmission elements!
n Assembly of clutches and othertransmission elements according to theinstructions. To prevent damage of thebearings, avoid under all circumstancesimpacts on shafts and exceeding of thepermissible radial and axial forces!
¯ Ensure sufficient space for unimpededmaintenance.
5.4 Electrical connectionn Make electrical connections only when novoltage is applied! Danger of unintendedstartings or electrical shocks.
n Electrical connections must only be madeby skilled personnel.
¯ Operate DC shunt motors only at DCvoltage. The supply is normally via DCspeed controllers. Make sure that thesupply voltage / controller output voltage isidentical with the nameplate data.
¯ A separate blower, which may beconnected, requires a single--phase orthree--phase AC voltage according to thenameplate.
¯ A spring--loaded brake, which may beattached, requires a suitable DC voltage oran AC voltage which corresponds to theconnected rectifier.
¯ Dimension the connecting cablessufficiently large to avoid anon--permissible heating.
current [A] ≤6 ≤10 ≤16 ≤20 ≤25 ≤35 ≤50
Cable
cross-section
[mm2]
0.75 1 1.5 2.5 4 6 10
Rated
current in [A]≤63 ≤80 ≤100 ≤125 ≤160 ≤200 ≤250
Cable
cross-section
in [mm2]
16 25 35 50 70 95 120
When the cables are very long, select across--section one size larger to reducelosses.
¯ The motor cable cannot be protected bythe thermal sensors of the motor winding.Provide measures according to DIN 57100/ VDE 0530.
¯ Make electrical connection according tothe connecting diagram which is attachedto every motor. The connecting diagramsfor the standard factory design are shownin fig. 2 and fig. 3.
5.2
5.3
10
K33.0008
CW rotation CCW rotation
Fig. 2: Motor connecting diagram for the motor types MGFRK, MGERK, MGSRK, MGFQK,MGEQK, MGSQK (compensated design with commutating pole winding)
K33.0009
CW rotation CCW rotation
Fig. 3: Motor connecting diagram for the motor types MGFQU, MGEQU, MGSQU(uncompensated design with commutating pole winding)
11
5.5 Parts for attachmentn Attach parts to the drive only when novoltage is applied!
n Remove loads from the motor or secureloads acting on the drive!
n Do not use hammers or other impact toolsfor assembly and dismantling!
¯ Motors with B--side attachments (brakesand/or feedback sources) are assembled,electrically connected and checked fortheir function. Observe suitable operatinginstructions.
¯ When brakes and/or feedback sources areretrofitted, observe the followingconnecting designations for additionaldevices and attachments, the suitableinstallation instructions and operatinginstructions.
Connecting designations of additional devices and attachments to the terminal board orterminal strips
Attachments Terminal Connection
Protective earth (SL)Ground
External blower 1µ U1U2
Connection to L1 - mainsConnection to N - mains
External blower 3µU1V1W1
Connection to L1 - mains Observe direction of rotation!Connection to L2 - mains InterchangeConnection to L3 - mains L1 - L2 in case of incorrect rotation
DC tacho +-
2A12A2 Polarity with CWrotation
AC tacho with rectifier +-
3A13A2 Polarity independent of the direction of rotation
Thermal contact (normally closed) max. 250Vµmax. 1.6 Aµ
S1S2
Warning 1S1 switch-off 2S1Warning 1S2 switch-off 2S2
Thermal contact (normally open) max. 250Vµmax. 1.6 Aµ
S3S4
Warning 1S3 switch-off 2S3Warning 1S4 switch-off 2S4
PTC P1P2
Warning 1P1 switch-off 2P1Warning 1P2 switch-off 2P2
Brake DC excitation +-
Y1Y2
Brake rectifier
14
2+3-
Connection to L1 - mainsConnection to N - mainsConnection to brake Y1 (+)Connection to brake Y2 (-)
Brush indicator (normally closed) Max. 28 V -max. 4 A -
1H11H2 isolated
Brush indicator (normally open) Max. 28 V -max. 4 A -
1H31H4 isolated
Brush indicator (normally closed) Max. 28 V -max. 4 A -
2H32H4 not isolated 1st indication circuit
Brush indicator (normally open) Max. 28 V -max. 4 A -
3H33H4 not isolated 1st indication circuit
Standstill heating E1E2 24 V
Standstill heating E3E4 230V
Pulse encoder
Supply +Supply -Output channel AOutput channel AOutput channel BOutput channel BOutput channel COutput channel CEarthScreenAnalog output
B1B2B3B4B5B6B7B8B9B10B11
SupplyGND (ground)
Inverse
InverseZero trackInverse
Resolver - Connection via system cable, connecting diagrams are attached tothe drive
12
6. Commissioning and operationn Do not operate in hazardous areas!
n Depending on the operating state, thesurface temperature can exceed 90 5C.Keep cooling times!Do not touch motor surface if drives are inoperation!Provide protection against skin contact ifnecessary!
n Fire risk! Do not spray or clean drives withinflammable detergents or solvents!
n Avoid overheat!Deposits on drives obstruct the requiredheat dissipation and must be removed inintervals.
6.1 Checking before commissioningn Check the drive only when no voltage isapplied!
Check the following items before¯ the first commissioning
¯ commissioning after a long periodstandstill
¯ commissioning after maintenance of themotor
-- firm connection of the screws of themechanical and electrical parts
-- completeness of the set of carbonbrushes
-- easy sliding of the carbon brushes inthe brush holders
-- contact of all brush holder springs onthe carbons
-- if an oxyde layer has deposited on thecollector surface:Grind using a collector hand finishingstick or a corundum brick. Never usesolvents for cleaning.
-- brush in ”neutral position” (colouredmark at the brush yoke and at theendshield must coincide)
-- sufficient insulation resistance (seechapter 6.1.1)
-- unimpeded inlet and outlet of cooling air-- efficiency of the protections againstoverheat (checking the thermal snesors)
-- direction of rotation of the separateblower
6.1.1 Measuring the insulation resistance¯ To measure the insulation resistance,disconnect the connecting cables.Earth the winding parts which are not to bechecked and the thermal sensor.
¯ Check the following insulation resistances:
-- across rotor and stator windings-- across brush rulers with lifted brushesand across earth
¯ Test voltage:highest rated motor voltage or 500 V
¯ Test temperature:test motor housing for ambient temperature
Minimum insulation resistances:
¯ New motor:The insulation resistance in kWmust be atleast as high as the highest rated motorvoltage. Example:
UA = 460 V; Uf = 360 V⇒insulation resistance RI≥ 460 kW
When the resistance is smaller, dry themotor before commissioning.
¯ Recommissioning:The insulation resistance of a motor whichhad been in operation already, must be atleast 50 kW.
When the resistance is smaller, clean thewindings and the area of the collector andbrushes. After a long period of standstill,an additional drying may be necessary.
Possible procedure for drying:
1. Use a blower to blow dry, warm air of 80 5Cfrom the B--side through the motor.If possible, slowly rotate the rotor.
2. Allow housing to cool to ambienttemperature
3. Measure insulation resistance
4. Repeat drying procedure until theinsulation resistance has obtained therequired value.
13
6.2 Function testCaution !Apply armature voltage only when excitation voltage isapplied!When the voltage is applied without an excitation voltagebeing applied to the motor, the motor may be destroyeddue to overspeed, i.e. the motor speed may rise until therotor is destroyed.
¯ Commission the drives and check allindividual functions, such as
-- torque behaviour and currentconsumption
-- braking of the attached brake-- output signal of the feedback system
¯ in case of malfunctions or interferences:trouble--shooting according to chapter 6.4.
6.3 Inspection¯ We recommend to inspect drives inoperation every 50 operating hours.Observe:
-- loud noises-- excessive surface temperatures-- oily drive parts or leakages-- changed speeds etc.
¯ In case of irregularities:see trouble--shooting chapter 6.4.
14
6.4 Fault -- Cause -- Remedyn Maintain and repair the drive only when novoltage is applied!
n High temperatures of the motor surfaces.Keep cooling times!
n Remove loads from the motor or secureloads acting on the drive!
Interferences
Fault Cause Remedy
M t d t t t P l i t t d Ch k l t i l ti ( h t 5 4)Motor does not start Power s pply interr pted Check electrical connection (chapter 5 4)Motor does not start Power supply interrupted Check electrical connection (chapter 5.4)Motor does not startController inhibited Check controller display check controller enableController inhibited Check controller display, check controller enable
No carbon br shes or not correctly installed Check if br sh set complete and placed correctlyNo carbon brushes or not correctly installed Check if brush set complete and placed correctlyNo carbon brushes or not correctly installed Check if brush set complete and placed correctly(chapter 7.1)(chapter 7.1)
Armat re coils defective or short-circ ited Remove short circ it (often only possible is a specialArmature coils defective or short-circuited Remove short circuit (often only possible is a specialworkshop or by the man fact rer)workshop or by the manufacturer)
Excitation winding interr pted Remove interr ptionExcitation winding interrupted Remove interruption
Motor does not start Brake does not release Check electrical connectionMotor does not start(high c rrent cons mption)
Brake does not release Check electrical connection(high current consumption) Check air gap ’sL ’ (see operating instr ctions of the(high current consumption) Check air gap ’sLü’ (see operating instructions of the
brake)brake)
Magnetsp le berpr fenMagnetspule überprüfen
Drive is blocking Check for free r nning of components ( remove foreignDrive is blocking Check for free running of components ( remove foreignmatter if necessary)matter, if necessary)
S rface temperat re > 90 5C Overload of the drive Check c rrent cons mption check load and red ce ifSurface temperature > 90 5C Overload of the drive Check current consumption, check load and reduce, ifnecessarynecessary
H t di i ti b t t d b d it Cl f f th d iHeat dissipation obstr cted by deposits Clean s rface of the driveHeat dissipation obstructed by deposits Clean surface of the driveCooling d cts inside the motor are obstr cted Remove deposits inside the motorCooling ducts inside the motor are obstructedby deposits
Remove deposits inside the motorby deposits
Motor s ddenly stops and does not Thermal contact interr pts power s pply Red ce load allow motor to cool (for cleaning seeMotor suddenly stops and does notstart again
Thermal contact interrupts power supply Reduce load, allow motor to cool (for cleaning seeabove)start again above)
Check cooling effect (direction of rotation) of theCheck cooling effect (direction of rotation) of theseparate blower
Clean or replace filter element of the separate blowerClean or replace filter element of the separate blower
Uneven r nning motor stops for a Carbon br shes are worn Replace br sh set (chapter 7 1)Uneven running, motor stops for ashort time
Carbon brushes are worn Replace brush set (chapter 7.1)g, pshort time Carbon br shes are jamming abrasive matter Cleaning of the inner part (chapter 7 1)short time Carbon brushes are jamming, abrasive matter
in the g idanceCleaning of the inner part (chapter 7.1)
in the guidance
Winding contact in the armat re windings Repair in the workshop or by the man fact rerWinding contact in the armature windings Repair in the workshop or by the manufacturer
Bar contact at the collector Check collector and remove contact between the barsBar contact at the collector Check collector and remove contact between the bars
Uneven running (vibrations) Insufficient balancing of coupling elements or RebalancingUneven running (vibrations) Insufficient balancing of coupling elements orworking machine
Rebalancing
I fi i t li t f th d i t i R li hi t h k b ifIns ficient alignment of the drive train Re-align machine set check base if necessaryInsuficient alignment of the drive train Re-align machine set, check base, if necessaryFixing screws are not tightened Check screw connections and sec reFixing screws are not tightened Check screw connections and secure
Excessive speed motor oscillates n Br sh yoke shifted from the ne tral zone Coincide colo r label at the br sh yoke and endshieldExcessive speed, motor oscillates un- Brush yoke shifted from the neutral zone Coincide colour label at the brush yoke and endshieldExcessive speed, motor oscillates un-der load
Brush yoke shifted from the neutral zone Coincide colour label at the brush yoke and endshieldder load
Interference of excitation current circuit Check excitation current and voltage, eliminate causeInterference of excitation current circuit Check excitation current and voltage, eliminate causeof interference
Noise Carbon br shes are not r n-in S pport r n-in (chapter 7 1)Noise Carbon brushes are not run-in Support run-in (chapter 7.1)
Foreign matter inside the motor Cleaning of the inside area of the motor, repair byForeign matter inside the motor Cleaning of the inside area of the motor, repair bymanufacturer, if necessary
Bearings damaged Replace bearings repair by man fact rer if necessaryBearings damaged Replace bearings, repair by manufacturer, if necessary
15
7. Maintenance / Repairn Maintain and repair the drive only when novoltage is applied !Disconnect drive from the power supply!
n High temperatures of the motor surfaces.Keep cooling times!
n Remove loads from the motor or secureloads acting on the drive!
n Make sure that no foreign matterpenetrates inside the motor duringmaintenance and repair!
7.1 Maintenance periodsCarbon brushes and in some cases alsocollectors are wear parts in commutatormachines.
¯ Service intervals:Since the abrasion of the carbon brushesstrongly depends on the operatingconditions, we recommend the followingintervals for checking:
-- 1st check after approx. 100 operatinghours
-- 2nd check after 300 more operatinghours
-- further tests depending on the wearwhich has been found. For safetyreasons, the service intervals should notexceed 1000 operating hours.
7.2 Wear check of carbon brushes¯ To remove the brushes the brush yoke ofsome motors must be disconnected androtated. The correct position of the brushyoke (neutral zone!) is marked by a colourmark at the brush yoke and the endshield.This mark must exactly coincide afterinspection or replacement of the brushes.
¯ We recommend to write down themeasured brush length.
¯ Check the quality and the appearance ofthe running surface of collector and carbonbrush, especially during the first check:
-- A homogenous film (patina) must havedeposited on the collector runningsurface.
-- The running surface of the carbonbrushes must be even and must notshow any ”blushings”, burnings orbroken edges.
-- If the result of the inspection is notsatisfactory, you can refer to chapter 7.4,find possible causes and eliminate them.In case of doubt, please contact theLenze Service.
16
Checking and replacing carbon brushes1. For MGXRK series:Dismantle blower hood and tighteningstrap.For MGXQU series:Dismantle cover sheets at the B--sideendshield.
2. Loosen carbon abrasion inside the motorusing a brush and suck off.Do not blow out, because the dust may beblown inside the motor and in the windingheads.
3. Take off spring of the brush holder, take outcarbon brushes and measure the length ofthe brushes:
-- The carbon brushes are marked withletters. The lower edge of the letters isthe wear limit.
-- If this limit is almost reached, alwaysreplace the carbon brushes in sets.Only use genuine carbon brushes orthose approved by the manufacturer,otherwise the commutation and brushlife are endangered (for orders seechapter 8.2).
4. Insert carbon brushes such that they easilyslide in the brush holders.Place the wires such that the carbons canslide without being obstructed, when theyare shortened due to wear.
5. To ensure a good electrial contact betweencarbon brushes and collector, grind thecarbon brushes such that they are adaptedto the collector diameter before the motoris commissioned:
-- For motors which have free access tothe shaft ends and where the rotors caneasily be rotated by hand (fig. 4,sketch 1):Fix abrasive paper or abrasive cloth ofgrain 180 or hold by hand.Insert the new carbon brushes andplace spring of the brush holder on thecarbon brushes.Then turn the rotor of the motor to bothsides until the contact surface of thecarbon brushes has completely adaptedto the running surface diameter of thecollector.
-- For heavy motors which are difficult tomove and those motors the shafts endsof which are not accessible, the carbonbrushes of each pole must be groundseparately (fig. 4, sketch 2):Lay a strip of abrasive paper or abrasivecloth of grind 180, the length of whichcorresponds to the length of thecollector running surface, between therunning surface and the brush holders ofa pole.
Insert the new carbon brushes andplace the spring on the carbon brushes.
By moving the abrasive paper under thecarbon brushes to both sides along thecollector shape, grind all carbonbrushes of a pole at the same time.
sketch 1 sketch 2
K33.0005
Fig. 4: Grinding of carbon brushes
6. Take carbon brushes out of the brushholders. Carefully remove grinding andcarbon dust.
7. Insert carbon brushes again.
8. After disconnecting and turning the brushyoke:
-- Set ”neutral zone” again. For this, themark at the brush yoke and theendshield must exactly coincide.Reconnect brush yoke.
9. For MGXRK series:Reassemble tightening strap and blowerhood.For MGXQU series:Reassemble cover sheets.
The motor is now ready to operate again.
17
7.3 Wear check of the collector¯ Under normal operating conditions, thecollector does not need specialmaintenance.Normally, the collector must only bemachined after several sets of carbonbrushes have been used.
¯ In case of strong ovality or clear burns, thecollector must be ground or dressed, ifnecessary. Normally a slight regrindingusing a collector finishing stick, which isadapted to the shape of the collectorrunning surface, is sufficient.
Dress the collector when:
-- the collector running surface showsclear chatter marks
-- the collector shows marks in the carbonbrush running surfaces of more than 0.3mm depth
-- the collector running surface is oval formore than 0.015 mmFor even ovality of the running surface,an ovality of 0.03 mm is acceptableduring operation.
-- the height (difference of the radius)between two bars next to each other ismore than 2 mm
-- there are strong burns at the bars or baredge
¯ The following minimum diameter of thecollector running surfaces must not beexceeded, otherwise a perfect operation isnot ensured.
Motor type Diameter of the collectdor running surfacesmm
new minimum
MGXRK 090-22 68.0 66.0
MGXRK 100-22 75.5 74.0
MGXRK 112-22 84.0 82.0
MGXRK 132-22 111.0 108.0
MGXRK 160-32 137.0 134.0
MGXQU 080-22 81.5 79.0
MGXQU 100-22 91.3 90.0
MGXQU 112-22 104.0 102.0
MGXQU 132-32 137.0 134.0
MGXQU 160-22 150.0 147.0
MGXQU 160-32 150.0 147.0
MGXQK 063-32 64.0 62.0
MGXQK 100-22 94.6 92.2
MGXQK 100-32 94.6 92.2
MGXQK 160-22 150.0 147.0
MGXQK 160-32 150.0 147.0
Dressing of the collector
1. Machine the running surface of thecollector using a sharp hard metal cuttingtool and minimum cutting rateCutting speed 250 -- 350 m/min
2. If necessary, remove insulation betweenthe collector bars as shown in figure 5:
-- The insulation between the collectorbars must be milled or sawn out up to1.00.3 mm
-- Milling width in the centre of theinsulation:0.1 to 0.2 mm wider than the offset of thebars, since residuals at the bar edgeswould cause sparking and increasedwear of the carbon brushes
-- Break collector bar edges slightly under605to 905after milling
3. Check the surface roughness of the bar,since carbon brushes tend to vibrate onvery smooth running surfaces which were”polished” using diamonds:
-- A surface roughness between 1.6 mmand 4 mm is permissible
-- When the surface roughness is less:Roughen the bar surface using fineabrasive paper or a fine grindstone toaccelerate the formation of patina
4. Use a brush to clean the insulation slotsand blow out using compressed air
K33.0004
copperinsulation
Fig. 5: Milling of the bar insulation at the collector
18
7.4 Recognition of incorrect operatingconditions
The function of the collector and the carbonbrushes is influenced by many factors. Forexample humidity, pollutants in the air in theform of gases, oil or solvent spray etc. as wellas a very low temperature of the cooling air,low loads over a long time or vibrations actingon the motor are decisive factors for thecommutation and wear of collector andcarbon brushes.A prerequisite for a good function of thecarbon brushes is the right choice of thebrush material and the correct totalcross--section of the carbon brushes of eachpole, which must be perfectly adapted to the
motor and the operating conditions of themotor.Lenze have a long experience inmanufacturing motors and selecting optimumcarbon brushes. For special operating /ambient conditions the brush material and thenumber of carbon brushes can be adaptedfor an optimum wear.Before selecting another type of carbonbrushes, always contact the Lenze Service.In the following, some troubles, possiblecauses and measures to improve thecommutation and the wear are listed:
Fault Cause Remedy
Sparking,increased brush wear,black coarse spots on the collector s rface
Penetration of oil or oil spray Avoid penetration of oil into the collector areaby sealing
black, coarse spots on the collector surfaceRemove pollutions
Slightly grind the collector and thoroughlyclean carbon brushes
Sparking,chatter marks on collector and carbon brushr nning s faces
Solid dust particles under the carbon brushescause chatter marks
Where necessary, ensure efficient protectionagainst dust using filter elements
running sufacesSupply motor with clean cooling air via a tubesystem
Sparking,collector surface has the colour of copper,increased wear
Formation of patina impossible because ofvery dry air
Increase humidity by air-conditioning of theoperating rooms or by other measures
Insufficient or missing patina,run-in marks at the collector
Temperature of the collector surface and thecarbon brushes too low for the formation ofpatina
Increase ambient temperature and thus thecooling air temperature
Very low cooling air temperature or motoroperation with a considerably lower loadcurrent than the rated current over a long time
Reduce carbon brushes according to the loadContact the Lenze Service
Strong sparking,bl e or green lights
High motor overload Reduce motor loadblue or green lights,burns at the bar edges and chipping at theedges of the carbon brushes
Check field supply,measure armature current and adapt to therated current
Sparking,excessive wear of carbon brushes,collector with clear chatter marks
Operation in rooms with chemically pollutedatmosphere
Supply motor with clean cooling air usingsuitable filter elements or supply of externalfresh air
Sparking,burnings at the collector,increased wear
Insufficient contact between carbon brushesand collector
Clean collector in regular intervals
increased wearAcumulation of carbon dust and otherpollutants
Check if carbon brushes can easily slide in thebrush holders
Missing pressure Ensure easy sliding of the carbon brushes withcontinuing wear
Reduction of the pressure by high accelerations Fit stronger springs in the motor
19
7.5 Waste disposal of the productn Note: Use raw material for recycling
Separate waste disposal according to thedifferent materials:
¯ Motor
A-side endshield: Aluminium for MGXQK 063-32
Aluminium diecast for MGXRK 090 - 112
Others: grey cast iron
Cover sheets: Steel sheet (sometimes zinc coated)
B-side endshield: Aluminium for MGXQK 063-32
Aluminium diecast for MGXRK 090 - 112
Others: grey cast iron
Brush yoke: Polyamide P46 glass-fibre reinforced
Carbon holder: Brass
Carbon brushes: Carbon, graphite, copper,
Sometimes synthetic resin
Wires: Copper with EVA sheath
Tubes: Glass fibre tube with enamelled poly-urethane
Tightening strap: Steel sheet (zinc coated) with rubber
(for MGXRK motors)
Cover sheets: Steel sheet (sometimes zinc coated)
(for MGXQU and MGXQK motors)
Housing: Steel for MGXQK 063-32
Aluminium diecast for MGXRK 090 - 112
Grey cast for MGXRK 132 - 160
Laminated sheets: Dynamo sheet
Winding: Enamelled copper wire
Insulation: Polyamide, epoxy resin, paper
Terminal box: Grey cast for MGXRK 132 - 160
Polyester glass fibre reinforced for
MGXQU / MGXQK 160
Others: aluminium diecast
Terminal board: Polyester glass fibre reinforced
Seals: NBR or paper
Rotor shaft:
Shaft: Steel
Collector: Copper, steel, phenole resin
Bearings, screws, washers,nuts:
Steel
¯ B--side attachments:See suitable operating instructions
20
8. Spare parts
8.1 Spare parts lists¯ Roller bearings
Motor type A-side B-side
normal bearing reinforced bearing normal bearing reinforced bearing
TypePart no.
TypePart no.
TypePart no.
TypePart no.
MGXRK 090-22 6205-2RSR-C3333 043
NU205ECP333 304
6205-2RSR-C3333 043
6205-2RSR333 352
MGXRK 100-22 6206-2RSR-C3333 112
NU206ECP311 490
6206-2RSR-C3333 112
6206-2RSR333 111
MGXRK 112-22 6306-2RSR-C3333 204
NU306ECP311 488
6206-2RSR-C3333 112
6206-2RSR333 111
MGXRK 132-22 6308-2RSR-C3333 109
NU308ECP311 489
6308-2RSR-C3333 109
6308-2RSR333 106
MGXRK 160-32 6310-2RSR-C3333 205
NU310ECP330 868
6309-2RSR-C3333 110
6309-2RSR333 105
MGXQU 080-12 6305-2RSR-C3333 203
NU305ECP369 136
6205-2RSR-C3333 043
6205-2RSR333 352
MGXQU 080-22 6305-2RSR-C3333 203
NU305ECP369 136
6205-2RSR-C3333 043
6205-2RSR333 352
MGXQU 100-22 6306-2RSR-C3333 204
NU306ECP311 488
6206-2RSR-C3333 112
6206-2RSR333 111
MGXQU 112-12 6308-2RSR-C3333 109
NU308ECP311 489
6307-2RSR-C3333 108
6307-2RSR333 107
MGXQU 112-22 6308-2RSR-C3333 109
NU308ECP311 489
6307-2RSR-C3333 108
6307-2RSR333 107
MGXQU 132-32 6308-2RSR-C3333 109
NU308ECP311 489
6308-2RSR-C3333 109
6308-2RSR333 106
MGXQU/K 160-22 6312-2RSR-C3334 612
NU312ECP336 681
6312-2RSR-C3334 612
6312-2RSR336 682
MGXQU/K 160-32 6312-2RSR-C3334 612
NU312ECP336 681
6312-2RSR-C3334 612
6312-2RSR336 682
MGXQK 063-32 6204-2RSR-C3332 379 --- 6204-2RSRC3
332 379 ---
MGXQK 100-22 6306-2RSR-C3333 204
NU306ECP311 488
6206-2RSR-C3333 112
6206-2RSR333 111
MGXQK 100-32 6306-2RSR-C3333 204
NU306ECP311 488
6206-2RSR-C3333 112
6206-2RSR333 111
21
¯ Spare parts list carbon brushes and brush yokes
Motor type B-side Time
Brush yoke Carbon brushes
Part no. Dimensions No.
MGXRK 090-22 323 436 6.3x12.5x20328 873 4 before
31.01.94
348 917 6.3x12.5x20328 873 4 as from
01.02.94
MGXRK 100-22 326 542 8x12.5x20328 876 4 before
28.02.89
323 437 8x12.5x20328 875 4 as from
01.03.89
MGXRK 112-22up to 20 (A) 320 388 8x12.5x20
328 876 4
as from 20 (A) 323 319 8x10x20328 874 8
MGXRK 132-22up to 27 (A) 310 037 10x16x25
328 879 4
as from 27 (A) 320 383 10x12.5x20328 878 8
MGXRK 160-32up to 32 A 328 839 10x16x32
329 624 8
as from 32 A 328 839 10x16x32329 624 4
MGXQU 080-12 337 795 8x16x25337 802 4
326 542 8x12.5x20328 876 4 before
28.02.89
MGXQU 080-22 323 437 8x12.5x20328 875 4
as from01.03.89
before31.07.92
337 795 8x16x25337 802 4 as from
01.08.92
MGXQU 100-22 329 076 10x12.5x25329 176 8 before
31.07.92
up to 32 (A) 341 788 10x16x25337 801 4 as from
01.08.92
as from 32 (A) 337 796 10x16x25337 801 8 as from
01.08.92
MGXQU 112-12up to 32 A 347 131 10x16x25
347 135 4
as from 32 A 347 131 10x16x25347 135 8
MGXQU 112-22up to 25 A 320 383 10x12.5x20
328 878 4 before31.12.92
as from 25 A 320 383 10x12.5x20328 878 8 before
31.12.92
up to 32 A 347 131 10x16x25347 135 4 as from
01.01.93
from 32 A 347 131 10x16x25347 135 8 as from
01.01.93
MGXQU 132-32up to
90 (A) 329 328 10x20x32329 393 8
90-120 (A) 332 197 12.5x20x32328 880 8
332 197 12.5x20x32330 880 8
Motor type B-side Time
Brush yoke Carbon brushes
Part no. Dimensions No.
MGXQU/K160-22 333 609 12.5x25x32
334 607 4
up to 70 (A) 333 609 12.5x25x32334 607 8
up to 120 (A) 333 609 12.5x25x32334 607 12
from 120 (A) 333 60912.5x25x32Z
w336 699
12
MGXQU/K160-32 333 609 12.5x25x32
334 607 4
up to 70 (A) 333 609 12.5x25x32334 607 8
up to 120 (A) 333 609 12.5x25x32334 607 12
from 120 (A) 333 60912.5x25x32Z
w336 699
12
MGXQK 063-32 333 703 6.3x16x20333 780 4
MGXQK 100-22 329 669 10x12.5x25329 765 8
MGXQK 100-32up to 27 (A) 329 076 10x12.5x25
329 176 4
from 27 (A) 329 076 10x12.5x25329 176 8
22
8.2 Ordering example for spare partsWhen ordering spare parts, please indicate atleast:¯ Designation of the spare parts¯ Required number of pieces¯ Data of the motor nameplate
(chapter 4.4):-- Motor type-- Commission number (K.-- Nr.)-- Motor number (Mot.-- Nr.)-- Rated current (IN)
When indicating the designation of the sparepart, please observe a possible specialcarbon brushes of your motor.Recommendation: Take a carbon brush out ofyour motor and check whether it is a standardpart according to the spare part list above orwhether it is a special carbon brush.
Ordering example for a set of carbon brushes of a motor type MGFRKBT132--22 with IN=28.0 A
-- Carbon brush part no. 328 878-- 8 pieces-- Comm no: 4 / 39610-- Motor no.: 0257181-- IN: 28,0 A
Lenze GmbH & Co KGHans--Lenze--Straße 1, D--31855 Aerzen
MGFRKBT132--224/39610 0257181
G
28,0
T374595
23
24
Manufacturer’s Declaraction
25
26
27
Service addresses
Lenze GmbH & Co KG, Postfach 10 13 52, D-31 763 Hameln, Standort : Gross Berkel, Hans--Lenze Straße 1, D--31 855 AerzenTelefon (0 51 54) 82--0, Telefax (0 51 54) 40 40, Telefax Kundendienst/Service (0 51 54)82 2335
Printed in Germany by Lenze VLEX / 06.97